RECOMMENDATION REPORT TO CHOOSE THE BEST 5-AXIS COMPUTER NUMERICAL CONTROL (CNC) CUTTING MACHINE FOR RAPID MANUFACTURING

Submitted to: Pn. XXXXXX Lecturer Department of Languages Centre of Languages and Human Development Universiti Teknikal Malaysia Melaka

Prepared by: TAYALAN S/O MANOHARAN XXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXX (B041010129 (B04XXXXX (B04XXXXX (B04XXXXX (B04XXXXX 2BMCT 2) 2BMCT 2) 2BMCT 2) 2BMCT 2) 2BMCT 2)

8 March, 2012

EXECUTIVE SUMMARY

Tuah Steel Corporation (TSC) is the leading steel compartment company in Malaysia. TSC was established in 1988 and has steadily made its presence felt in the market through offering quality products and services. The purpose of this recommendation report is to compare between three type of cutting machine to recommend the best cutting machine to substitute the conventional cutting machine There are several important findings which we included in our report. Firstly, we would like to compare about the performance and job that can be done in one minute. Secondly, we also included about the purchase cost and maintenance cost including warranty. Finally, we compared on the space that need to install the machine and the maximum size of work piece with the speed to finish cutting one product.We have opened the tenders to supplier to submit the quotation, survey around the steel industry and collected information from internet to choose the best 5-axis cutting machine for our company. As a conclusion, we found out that Sodick Model AP 450L is the best choice and we have decided to recommend it to the company top management to buy it for the future of the company.

INTRODUCTION

1.1 Purpose

The purpose of this recommendation report is to compare between three type of cutting machine to recommend the best cutting machine to substitute the conventional cutting machine in Tuah Steel Corporation so that can increase our company productivity and save our company operating cost.

1.2 Methods

There are several methods which we had used in this two weeks time to get the information regarding about cutting machine. First of all, we open the tender to supplier to submit their quotation. Besides that, we also had done some survey at other steel company about the cutting machine. Finally, we collected some supporting data from the internet as an additional source. 1.3 Scope For comparing the cutting machine, we included some important criteria regarding about the cutting machine. There are several criteria which we included in our requirement. Firstly, we would like to compare about the performance and job that can be done in one minute. Other than that, we also included about the purchase cost and maintenance cost including warranty. Then, we compared on the space that need to install the machine and the maximum size of work piece with the speed to finish cutting one product.

1.4 Problem Statements Our company manage to get the new project to supply many types of raw material with various shape of product that require by Proton to manufacture cars for five years and the value for the project one year is about RM207 million. So we need to buy an advanced cutting machines to fulfill their requirement and also deliver the prodycts Just In Time(JIT).With the new technology cutting machine we can also increase our productivity and save a lot in operation cost.

DISCUSSION

3.1 Criteria

There are certain criteria that have been taken into consideration in comparing the 5axis cutting machine. They are operation material, cost of machine, material for cut, machine weight, the installation space for the machine, type of job for machine, tolerance, and speed to finish cutting one product and maintenance & warranty. All these criteria are based on the 5 axis cutting machine.

3.2 5-AXIS CNC (Computer Numerical Control) Laser Cut Machine

HAAS AUTOMATION Model L015-HA

CHARACTERISTIC

DETAILS

Operation Material

Maximum Size (Inch) Maximum load

120 X 60 X 0.98 2028 lbs./pallets

Specification Machine Travel Axis

Work support X Axis Y Axis Z Axis A Axis (tilt) B Axis (rot) Maximum mass load Maximum cutting speed Acceleration Cutting head Z-axis sensor

Metal plate 3048 mm 1016 mm 762 mm 32 32

Machine Specification

Cost of machine Type of job for machine can cutting Material for cut Skill to operate it

2,028 lbs X,Y,Z: 4724/min X,Y: 1.5G ; Z: 3G Cartridge type cutting head AMNC/PC Machine: 51kVA, Oscilator: Power 55kVA, Chiller: 27kVA Machine weight 28,860 lbs Full opening enclosure, CNC assist gas control, CNC focus Standard equipement control, oil shot, cut process monitoring USD 3,500,000
All

Mild Steel Training Technician (using computerized system)

Space to fix on the machine on one place

Speed to finish cutting one product. Tolerance (minimum)

134.64/min
+_ 0.001mm

Standby Mode

Running Mode

Performance

Maintenance & Warranty

Not required maintenance Laser lens = 2 years Component Mechanical = 1 year

3.3 5-Axis CNC (Computer Numerical Control) Wire Cut Electrical Discharge vvvMachine (EDM)

Sodick Model AP 450L

CHARACTERISTIC DETAILS

Operation Material Specification Machine Travel Axis

Maximum Size(Inch) Maximum load Work support X Axis Y Axis Z Axis U Axis

24 X 16 X 5 220 lbs./pallets Metal plate 450 mm 300 mm 150 mm 35 mm

V Axis

35 mm 220 lbs X,Y,Z: 589.5/min X,Y: 4.9G ; Z: 7.8G Wire with diameter 0.5mm0.30mm and wire tension 3N25N Rotating/Simultaneuos Movement Machine: 45kVA, Oscilator: 35kVA, Chiller: 20kVA 14110 lbs Automatic water level and wire threader control,Active Power Restart(UPS),15TFT Screen,dielectric cooling unit,linear motor cooling unit and remote controller. USD 1,500,000 All All Training Technician (using Intelligent Qvic EDM) 4000 x 3700 x 1800

Machine Specification

Maximum mass load Maximum cutting speed Acceleration Cutting head W-axis sensor Power Machine weight Standard equipement

Cost of machine Type of job for machine can cutting Material for cut Skill to operate it Space to fix on the machine on one place(mm) Speed to finish cutting one product. Tolerance (minimum) Performance

589.5/min

+_ 0.001mm

Energy save circuit are attach with SODICK Fine Corner Control,3D LP Control LP1W,Highspeed electrolysis control, Fine Pick-Up Function(FTII) and oil dielectric. Ten years of guarantee in case of non-human damage

Maintenance &

Warranty

3.3 5-Axis CNC (Computer Numerical Control) Water Jet Cut Machine

Flow March 4 Customizable 5 Axis Waterjet

CHARACTERISTIC DETAILS

Operation Material Specification Machine Travel Axis

Maximum Size(Inch) Maximum load Work support X Axis Y Axis Z Axis A Axis (tilt) B Axis (rot) Maximum mass load Maximum cutting speed Acceleration Cutting head Power Machine weight Standard equipement

100 X 40 X 8 2781 lbs./pallets Metal and Non-metal plate 2540 mm 1016 mm 204 mm 180 180 2781 lbs X,Y,Z: 3581/min X,Y: 1.75G ; Z: 2.81G Nozzle with high pressure flow rate Machine: 220V AC 5512 lbs Siemens 840D CNC or FANUC 30i controllers,volatage stabilizer and 17LCD screen. USD 4,000,000 All

Machine Specification

Cost of machine Type of job for machine can cutting Material for cut

Stainless steel, aluminum, copper, titanium, brass, bronze and

Skill to operate it Space to fix on the m/c on one place(mm) Speed to finish cutting one product. Tolerance (minimum) Performance

non- metal materials like glass, plastics, stone and wood. Training Technician (using computerized system) 2300 x 2200 x 1800

393.7/min +_ 0.001mm
Setup and fixturing in just a few minutes with no side forces required. Different jobs do not require different tooling through robotic, software-controlled systemsnot hard tooling. Cool-cutting process allows stacking raw materials and cutting multiple parts in one pass.5 axis waterjet cutting offers the advantage of multiple cutting heads, which increases productivity 5 years warranty

Maintenance & Warranty

CONCLUSION
The maintenance & warranty offered are 10 years compared to Flow March 4 Customizable 5 Axis Waterjet, 5 years and Haas Automation Model L015-Ha 1 year.

Besides that, cost of machine offered by Sodick Model AP 450L,RM1.5 million is cheaper than Flow March 4 Customizable 5 Axis Waterjet and Haas Automation Model L015-Ha which will give us as much as RM4 million and RM 3.5 million. In terms of type of job for machine, tolerance, and speed to finish cutting one product the Sodick Model AP 450L have better efficiency and accuracy compared to Flow March 4 Customizable 5 Axis Waterjet and Haas Automation Model L015-Ha where it can cut all type of materials with complex shape at 589.5/min with accuracy +-0.001 mm. The space require to fix the machine for Sodick Model AP 450L ,Flow March 4 Customizable 5 Axis Waterjet and Haas Automation Model L015-Ha are 4000 x 3700 x 1800 (mm),2300 x 2200 x 1800 (mm) and 7214 x 5004 x 2439 (mm) so the most compatible machine for using the space is Flow March 4 Customizable 5 Axis Waterjet.

RECOMMENDATION
We recommend Sodick Model AP 450L, which meets all of our criteria. The maintenance & warranty offered are 10 years compared to others. Besides that, cost of machine offered by Sodick Model AP 450L is cheaper than Flow March 4 Customizable 5 Axis Waterjet and Haas Automation Model L015-Ha which will give us as much as RM4 million and RM 3.5 million. In terms of type of job for machine, tolerance, and speed to finish cutting one product the Sodick Model AP 450L have better efficiency and accuracy compared to Flow March 4 Customizable 5 Axis Waterjet and Haas Automation Model L015-Ha. This machine is very good for our company development which wants to save operation cost. So, we would like to recommend that Sodick Model AP 450L is the better choice for our company where the limitations of the machine is the advantage to us .

REFFERENCES